owners manual bell 206l-407 hook kit 120-046-00

Cargo Hook Kit For The

Bell 206L Series Helicopter Bell 407 Series Helicopters

Part Number 200-215-00

Owner's Manual

Owner's Manual Number 120-046-00

Revision 13

September 15, 2009

13915 NW 3rd Court, Vancouver Washington, 98685 Phone: 360-546-3072 Fax: 360-546-3073 Toll Free: 800-275-0883

www.OnboardSystems.com

This page intentionally left blank.

RECORD OF REVISIONS

Revision

Date

Page(s)

Reason for Revision

6 10-31-00 1-1

2-2

Added Talon LC Service Manual to BOM and New

STC dated July 27, 2000

Revised instructions of manual release cable

installation and Figure 2-2.

7 5-30-01 2-1

3-5

RFMS Pg. 2

Replaced hook picture to show new cover and S/N

plate.


plate.


plate

8 12-10-02 Title, 4-3 Address Change

9 07-19-05 Section 4 Removed maintenance information and replaced with

reference to Service Manual 122-001-00.

10 08-18-06 1-1, 2-4,

Section 5

Removed RFMS from manual. A separate document,

121-036-00, has been created for it.

11 11/20/06 1-1 & 2-4 Changed Cargo Hook P/N 528-010-00 to 528-010-04

per service bulletin 159-017-00.

Added paragraph to address Release Fitting (290-331-

00) in Maintenance section.

12 10/01/07 TOC, Section 1,

2-3 & Section 3

Added explanation or warnings, cautions and notes to

general information section. Updated warnings,

cautions and notes throughout document.

13 09/15/09 1-2,1-3,2-2 Added Release Cable Assembly (P/N 268-004-01) to

kit.

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i

CONTENTS Section 1 General Information

Introduction, 1-1

Warnings, Cautions and Notes, 1-2

Bill of Materials, 1-2

Inspection, 1-2

Specifications, 1-3

Theory of Operation, 1-3

Section 2 Installation Instructions Cargo Hook Removal, 2-1

Cargo Hook Installation, 2-1

Suspension System Installation Check-Out, 2-4

Component Weights, 2-4

Cargo Hook Location, 2-4

Paper Work, 2-4

Section 3 Operation Instructions Operating Procedures, 3-1

Cargo Hook Rigging, 3-2

Section 4 Maintenance Instructions for Returning a System to the Factory, 4-1

Section 5 Certification STC, 5-1

Canadian STC, 5-3

EASA STC, 5-4

ii

CONTENTS, continued

Figures 2-1 Suspension System Overview, 2-1

2-2 Manual Release Cable Rig, 2-2

2-3 Un-commanded Release From Incorrectly Secured Cable, 2-3

3-1 Examples of Correct and Incorrect Cargo Hook Rigging, 3-3

3-2 Un-commanded Release Due to Large Load Ring, 3-4

3-3 Load Hang-Up, Too Small or Multiple Load Rings, 3-5

3-4 Un-Commanded Release Due to Nylon Straps, 3-6

3-5 Un-Commanded Release Due to Cable or Rope Straps, 3-7

Tables 1-1 Specifications, 1-3

2-1 Cargo Hook Connector, 2-2

2-2 Cargo Hook Location, 2-4

General Information 1-1

Section 1

General Information Introduction

The 200-215-00 Cargo Hook Kit is approved for installation on the

following Bell helicopters:

Model Serial Numbers

206L 45001-45153

206L-1 45154 and on

206L-3 51001 and on

206L-4 52001 and on

407 all

Equipped with one of the following Bell Helicopter Cargo Hook

Suspension Systems:

206-706-341-109

206-706-341-5

206-706-341-101

The 528-010-04 Cargo Hook is suitable as a replacement for the following

cargo hooks when used on one of the applicable Bell Helicopter Cargo

Hook Suspension Systems listed above.

Breeze-Eastern Cargo Hook P/N

17149-6

17149-2

1-2 General Information

Warnings, Cautions and Notes

The following definitions apply to Warnings, Cautions and Notes used in

this manual.

Means that if this information is not observed,

serious injury, death or immediate loss of flight

safety could occur.

Means that there is a risk of injury or degradation

in performance of equipment if this information is

not observed.

Draws the reader’s attention to information which

may not be directly related to safety, but which is

important or unusual.

Bill of Materials The following items are included with the Cargo Hook, if shortages are

found contact the company from whom the system was purchased.

Part Number Description Quantity

120-046-00 Owner’s Manual 1

121-036-00 RFMS 1

122-001-00 Talon LC Cargo Hook Service Manual 1

290-331-00 Release Fitting 1

528-010-04 Cargo Hook 1

268-004-01 Release Cable Assembly 1

Kits manufactured after 9/15/09 include Release

Cable Assembly P/N 268-004-01.

General Information 1-3

Inspection

Inspect the cargo hook for evidence of damage, corrosion and security of

lock wire and fasteners. If damage is evident, do not use the unit until it

has been repaired.

Specifications

Table 1-1 Specifications

Design load 3,500 lb. (1,580 kg.)

Design ultimate strength 15,750 lb. (7,140 kg.)

Electrical release capacity 8,750 lb. (3,970 kg.)

Mechanical release capacity 8,750 lb. (3,970 kg.)

Force required for mechanical

release at 3,500 lb.

8 lb. Max.(.400” travel)

Electrical requirements 22-28 VDC 9 amps

Minimum release load 7 pounds

Unit weight 3 pounds (1.35 kg.)

Mating electrical connector PC06A8-2S SR

Theory of Operation

The primary elements of the Cargo Hook are the load beam, the internal

mechanism, and a DC solenoid. The load beam supports the load and is

latched through the internal mechanism. The DC solenoid and an external

manual release cable provide the means for unlatching the load beam.

The load beam is normally returned to its closed position after release of

the load by a spring in the internal mechanism. In the closed position, a

latch engages the load beam and latches it in this position. The load is

attached to the load beam by passing the cargo sling ring into the throat of

the load beam past a spring-loaded keeper, which secures the load.

To release the load, the latch is disengaged from the load beam. With the

latch disengaged, the weight of the load causes the load beam to swing to

its open position, and the cargo sling slides off the load beam. A spring in

the internal mechanism then drives the load beam back to its closed and

latched position.

A load release can be initiated electrically or mechanically. Normal

release is achieved by pilot actuation of the push-button switch in the

cockpit. When the push-button switch is pressed, it energizes the DC

solenoid in the cargo hook, and the solenoid opens the latch in the internal

mechanism. In an emergency, release can be achieved by operating a

mechanical release lever. A manual release cable attached to the lever

operates the internal mechanism of the cargo hook to unlatch the load

beam.

Installation Instructions 2-1

Section 2

Installation Instructions These procedures are provided for the benefit of experienced aircraft

maintenance facilities capable of carrying out the procedures. They must

not be attempted by those lacking the necessary expertise.

Cargo Hook Removal To remove the existing cargo hook from the suspension system disconnect

the electrical and manual release cables from the cargo hook. Remove the

cargo hook retaining bolt and separate the cargo hook from the suspension

system.

Cargo Hook Installation Verify that the part number of the cargo hook removed matches one of the

numbers on the list in section 1 of this manual. If it does not, do not

attempt to use the new cargo hook, contact the factory for clarification.

Inspect the suspension system to ensure that all components are in

serviceable condition before assembling the new cargo hook to the

suspension system and returning the system to service.

Install the new cargo hook to the suspension system, in the same manner

as the old hook was installed. (The cargo hook load beam should point to

the right side of the helicopter). Torque cargo hook attach bolt and nut to

50 in-lbs, then rotate nut to next castellation, not to exceed 110 in-lbs.

Insert and secure cotter pin.

Figure 2-1 Suspension System Overview

BEAM

CARRIAGE

CARGO HOOK

LOAD BEAM

CARGO HOOK

ATTACH BOLT

CARGO HOOK

2-2 Installation Instructions

Cargo Hook Installation, continued Remove the cargo hook manual release cover and connect the manual

release cable, P/N 268-004-01. Place the cable ball end fitting into the

hook manual release fork fitting as illustrated in Figure 2-1. Check that

there is a minimum of .125 inch free play at the fork fitting as shown in

Figure 2-2 with the manual release handle in the cockpit in the full down

position.

Figure 2-2 Manual Release Cable Rig

Connect the cargo hook electrical release cable connector to the Cargo

Hook. Listed below is the pin out for the cargo hook connector.

Table 2-1 Cargo Hook Connector

Pin Function

A Ground

B Power

Installation Instructions 2-3

Cargo Hook Installation, continued

Un-commanded cargo hook release will happen if

the manual and electrical release cables are

improperly restrained. The cables must not be the

stops that prevent the Cargo Hook from swinging

freely in all directions. If the Cargo Hook loads

cause the hook to strain against the manual

release cable the swaged end of the cable may

separate allowing the inner cable to activate the

cargo hook manual release mechanism. The result

is an un-commanded release. Ensure that no

combination of cyclic stick or Cargo Hook

position is restrained by the manual or electrical

release cables.

Figure 2-3 Un-commanded Release From Incorrectly Secured Cable

2-4 Installation Instructions

Suspension System Installation Check-Out

After installation of the Cargo Hook, perform the following functional

checks. Follow any Bell Helicopter instructions for the specific helicopter.

1. Ensure that the manual release cable assembly and the electrical

release cable have enough slack to allow full swing of the suspension

assembly without straining or damaging the cables.

2. Apply 10 - 20 pounds to the cargo hook load beam and pull the cargo

hook mechanical release, the cargo hook should release.

3. Close the cargo hook release circuit breaker and position the battery

switch to the ON position. Apply 10 - 20 pounds to the cargo hook

load beam and depress the cargo hook electrical release button, the

cargo hook should release.

4. See the Bell Helicopter service instructions that cover the original

cargo hook suspension system for additional instructions.

Component Weights The weight of the 528-010-04 Cargo Hook is 3 pounds (1.36 kgs). This is

approximately 1 pound lighter than the cargo hook it replaced.

Cargo Hook Location

Table 2-2 Cargo Hook Location

Fuselage Station 121.0

Paper Work Insert the Rotorcraft Flight Manual Supplement 121-036-00 into the

Rotorcraft Flight Manual. In the US, fill in FAA form 337 for the initial

installation. This procedure may vary in different countries. Make the

appropriate aircraft log book entry.

Operation Instructions 3-1

Section 3

Operation Instructions

Operating Procedures Prior to each job perform the following:

1. Ensure that the Cargo Hook has been properly installed and that the

manual and electrical release cables do not limit the movement of

the hook.

2. Be completely familiar with this manual, particularly the Cargo

Hook rigging section.

3. Be completely familiar with all Bell Helicopter cargo hook operating

instructions.

4. Activate the electrical system and press the release button to ensure

the cargo hook electrical release is operating correctly. The

mechanism should operate smoothly and the Cargo Hook must re-

latch after release. If the hook does not re-latch do not use the unit

until the difficulty is resolved.

The release solenoid is intended to be energized

only intermittently. Depressing the electrical

release button continuously in excess of 20 sec.

will cause the release solenoid to overheat,

possibly causing permanent damage.

5. Activate the release lever assembly located on the cyclic stick to test

the cargo hook manual release mechanism. The mechanism should

operate smoothly and the Cargo Hook must re-latch after release. If

the hook does not re-latch do not use the unit until the difficulty is

resolved.

See the Bell service instructions that cover the original Cargo Hook

installation for additional instructions.

3-2 Operation Instructions

Cargo Hook Rigging Extreme care must be exercised in rigging a load to the Cargo Hook. If

the load ring is too big it may work its way around the end of the load

beam and be supported for a time on the keeper and then fall free. If the

load ring is too small it may jam itself against the load beam during an

attempted release. The following illustrations show recommended

configurations and potential difficulties that must be avoided.

The examples shown are not intended to represent

all problem possibilities. It is the responsibility of

the operator to assure the hook will function

properly with the rigging.


Cargo Hook Rigging, continued

Figure 3-1 Examples of Correct and Incorrect Cargo Hook Rigging

Secondary Ring or Shackle5/8" Max. cross section

Load

Primary Ring

Incorrect Rigging Incorrect Rigging

Correct Rigging

Multiple Rings

on Load Beam

Multiple Rings

on Primary Ring

1.50" Primary Ring I.D.1.87"


Un-Commanded Release Due to Too Large of a Load Ring

Load rings that are too large will cause an un-

commanded release. The ring will flip over the

end of the load beam and flip the keeper up and

then fall free. Only correctly sized load rings must

be used. See examples below.

Figure 3-2 Un-Commanded Release Due to Too Large of a Load Ring

Load Ring flips over

the Load Beam and

gyrates.

The flip over often occurs

with long line operations

during landings and take offs.

Load Ring moves

inward and bears

against the keeper

The Keeper is forced

to rotate allowing the

Ring to slip off


Load Hang-Up Due to Too Small of a Load Ring or Multiple Load

Rings

Load rings that are too small or multiple load

rings will hang on the load beam when the load is

released. Only correctly sized load rings must be

used. See examples below.

Figure 3-3 Load Hang-Up Due to Too Small a Load Ring or Multiple Load Rings

Jammed Ring

Sling Load

Sling Load

Jammed Rings

Load Hang-Up Due to

Multiple Rings on Load

Beam


Un-Commanded Release Due to Nylon Type Straps

Nylon type straps (or similar material) must not

be used directly on the cargo hook load beam as

they have a tendency to creep under the keeper

and fall free. If nylon straps must be used they

should be first attached to a correctly sized

primary ring. Only the primary ring should be in

contact with the cargo hook load beam. See

examples below.

Figure 3-4 Un-Commanded Release Due to Nylon Type Straps


Un-Commanded Release Due to Cable or Rope Type Straps

Cable or rope type straps must not be used

directly on the cargo hook load beam. Their

braided eyes will work around the end of the load

beam and fall free. If cable or rope is used they

should be first attached to a correctly sized

primary ring. Only the primary ring should be in

contact with the cargo hook load beam. See

examples below.

Figure 3-5 Un-Commanded Release Due to Cable or Rope Type Straps

Maintenance 4-1

Section 4

Maintenance

Cargo Hook Kit P/N 200-215-00 includes the Cargo Hook and the Release

Fitting (P/N 290-331-00). The Release Fitting threads into the cargo hook

manual release side and interfaces with the helicopter’s existing manual

release cable. It requires no maintenance other than a check, prior to

external load operations, for damage and security.

For detailed maintenance of the Cargo Hook refer to Cargo Hook Service

Manual 122-001-00.

Instructions for Returning Equipment to the Factory

If an Onboard Systems product must be returned to the factory for any reason (including returns, service, repairs, overhaul, etc) obtain an RMA number before shipping your return.

An RMA number is required for all equipment returns.

To obtain an RMA, please use one of the listed methods.

Contact Technical Support by phone or e-mail ([email protected]).

Generate an RMA number at our website: http://www.onboardsystems.com/rma.php

After you have obtained the RMA number, please be sure to:

Package the component carefully to ensure safe transit.

Write the RMA number on the outside of the box or on the mailing label.

Include the RMA number and reason for the return on your purchase or work order.

Include your name, address, phone and fax number and email (as applicable).

Return the components freight, cartage, insurance and customs prepaid to:

Onboard Systems 13915 NW 3rd Court Vancouver, Washington 98685 USA Phone: 360-546-3072

mailto:[email protected]

http://www.onboardsystems.com/rma.php

Certification 5-1

Section 5

Certification STC

5-2 Certification

STC continued

Certification 5-3

Canadian STC

5-4 Certification

EASA STC

Certification 5-5

EASA STC continued

owners manual bell 206l-407 hook kit 120-046-00

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